Interfacing a Light Emitting Diode (LED) Module to a Heat Sink Assembly, a Light Reflector and Electrical Circuits

• US 20110019409A1
• Filed: 07/19/2010
• Published: 01/27/2011
• Est. Priority Date: 07/21/2009
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Wronski, Grzegorz
• Granted Patent: US 8,567,987 B2
• Time in Patent Office: Days
• US Class Current: 362/235
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 17/005 with keying means, i.e. for enabling the assembling of component parts in distinctive positions, e.g. for preventing wrong mounting
• CPC Class Codes: F21V 17/14 Bayonet-type fastening
• CPC Class Codes: F21V 19/0055 by screwing
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 29/503 of light sources cooling arrangements structurally associated with gas-discharge or vapour-discharge lamps H01J61/52; cooling arrangements structurally associated with electric incandescent lamps H01K1/58; cooling arrangements structurally associated with light-emitting diodes H01L33/64
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/713 in direct thermal and mechanical contact of each other to form a single system
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 7/00 Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21V 7/06 with parabolic curvature
• CPC Class Codes: F21V 7/24 characterised by the material
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A light emitting diode (LED) module is in thermal communication with front and back heat sinks for dissipation of heat therefrom. The LED module is physically held in place with at least the back heat sink. A mounting ring and locking ring can also be used to hold the LED module in place and in thermal communication with the back heat sink. Key pins and key holes are used to prevent using a high power LED module with a back heat sink having insufficient heat dissipation capabilities required for the high power LED module. The key pins and key holes allow lower heat generating (power) LED modules to be used with higher heat dissipating heat sinks, but higher heat generating (power) LED modules cannot be used with lower heat dissipating heat sinks.

Claims

1. An apparatus for illumination, comprising:

a light emitting diode (LED) module, the LED module comprising

a thermally conductive back,

a substrate having a plurality of light emitting diodes thereon and electrical connections thereto, and

at least one first key means and at least one first position means;

a back heat sink having heat dissipation properties and a thermally conductive face, at least one second key means and at least one second position means, wherein the at least one first and second key means and the at least one first and second position means cooperate together, respectively, so that the LED module cannot be used with a back heat sink not having sufficient thermal dissipation capacity necessary for removal of heat from the thermally conductive back of the LED module;

a mounting ring, wherein the mounting ring is attached to the back heat sink; and

a locking ring, wherein the locking ring secures the LED module to the mounting ring so that the LED module is located between the locking ring and the mounting ring, and the back of the LED module and face of the back heat sink are in thermal communication.

2. The apparatus according to claim 1, wherein thermally conductive material is used between the back of the LED module and the face of the back heat sink.

3. The apparatus according to claim 1, further comprising the LED module having a first electrical connector, and the mounting ring having a second electrical connector, wherein when the LED module is in the mounting ring the first electrical connector electrical connects to the second electrical connector.

4. The apparatus according to claim 1, wherein a smaller heat dissipation capacity back heat sink has more at least one second key means then a larger heat dissipation capacity back heat sink.

5. The apparatus according to claim 4, wherein the larger heat dissipation capacity back heat sink accepts both larger and smaller heat generating capacity LED modules, but the smaller heat dissipation capacity back heat sink will not accept the larger heat generating LED module.

6. The apparatus according to claim 1, wherein the LED module is properly oriented in the mounting ring and to the face of the back heat sink when the at least one first position means aligns with the at least one second position means.

7. The apparatus according to claim 1, further comprising:

a light reflector having mounting tabs perpendicular to a proximal end thereof;

at least one first mounting channel in an inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

at least one second mounting channel in the inner circumference of the LED module and substantially parallel with the substrate of the LED module; and

at least one third mounting channel in the inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

wherein the at least one first mounting channel, the at least one second mounting channel and the at least one third mounting channel connect at respective ends, and the at least one first mounting channel is open at the face of the LED module for accepting the mounting tabs when the light reflector is inserted into the LED module, then the light reflector is rotated through the at least one second mounting channel to the at least one third mounting channel having a closed end, whereby the mounting tabs are locked into the at least one third mounting channel at the closed.

8. The apparatus according to claim 7, further comprising at least one spring at the face of the LED module for mechanically biasing the mounting tabs of the light reflector into the at least one third mounting channel and for substantially centering the light reflector with the face of the LED module.

9. The apparatus according to claim 7, further comprising a front heat sink attached to and in thermal communication with the back heat sink, wherein the front heat sink surrounds the light reflector.

10. The apparatus according to claim 1, further comprising a light reflector attached to the locking ring, wherein the light reflector is substantially centered over the face of the LED module when the locking ring is attached to the mounting ring.

11. An apparatus for illumination, comprising:

a light emitting diode (LED) module, the LED module comprising;

a thermally conductive back,

a substrate having a plurality of light emitting diodes thereon and electrical connections thereto, and

tapered sides extending around a circumference of the thermally conductive back and in thermal communication therewith, wherein a back circumference of the tapered sides is greater than a front circumference of the tapered sides;

a back heat sink, wherein a front face of the back heat sink is attached to the thermally conductive back of the LED module and is in thermal communication therewith;

a front heat sink having a rear face and a cavity with sides protruding into the front heat sink, the cavity is centered in the front heat sink and is open toward a front face of the front heat sink, wherein the LED module fits into the cavity in the front heat sink such that the tapered sides of the LED module are in thermal communication with corresponding tapered sides of the cavity; and

the front heat sink is attached to the rear heat sink, wherein the LED module is held in the cavity between the back and front heat sinks, and the front face of the back heat sink and the back face of the front heat sink are in thermal communication.

12. The apparatus according to claim 11, wherein an angle of the tapered sides of the LED module are from about five (5) degrees to about thirty (30) degrees perpendicular to the thermally conductive back of the LED module.

13. The apparatus according to claim 11, further comprising:

a light reflector having mounting tabs perpendicular to a proximal end thereof, wherein the front heat sink surrounds the light reflector;

at least one first mounting channel in an inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

at least one second mounting channel in the inner circumference of the LED module and substantially parallel with the substrate of the LED module; and

at least one third mounting channel in the inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

wherein the at least one first mounting channel, the at least one second mounting channel and the at least one third mounting channel connect at respective ends, and the at least one first mounting channel is open at the face of the LED module for accepting the mounting tabs when the light reflector is inserted into the LED module, then the light reflector is rotated through the at least one second mounting channel to the at least one third mounting channel having a closed end, whereby the mounting tabs are locked into the at least one third mounting channel at the closed end.

14. The apparatus according to claim 13, wherein there are three each of the first, second and third mounting channels.

15. The apparatus according to claim 13, wherein each group of the connected first, second and third mounting channels are equidistantly spaced apart.

16. The apparatus according to claim 13, further comprising at least one spring at the face of the LED module for mechanically biasing the mounting tabs of the light reflector into the at least one third mounting channel.

17. The apparatus according to claim 11, wherein the front heat sink comprises a plurality of heat dissipating fins with air gaps therebetween.

18. The apparatus according to claim 11, further comprising thermally conductive material between the thermally conductive back of the LED module and the face of the back heat sink.

19. An apparatus for illumination, comprising:

a light emitting diode (LED) module, the LED module comprising

a thermally conductive back,

a substrate having a plurality of light emitting diodes thereon and electrical connections thereto, and

tapered sides extending around a circumference of the thermally conductive back and in thermal communication therewith, wherein a back circumference of the tapered sides is less than a front circumference of the tapered sides;

a back heat sink, wherein a front face of the back heat sink is attached to the thermally conductive back of the LED module and is in thermal communication therewith;

a front heat sink having a rear face and a cavity with sides protruding into the front heat sink, the cavity is centered in the front heat sink and is open toward a front face of the front heat sink, wherein the LED module fits into the cavity in the front heat sink such that the tapered sides of the LED module are in thermal communication with corresponding tapered sides of the cavity; and

the front heat sink is attached to the rear heat sink, wherein the LED module is in the cavity and holds the front heat sink to the back heat sink, and the front face of the back heat sink and the back face of the front heat sink are in thermal communication.

20. The apparatus according to claim 19, wherein an angle of the tapered sides of the LED module are from about one (1) degree to about eighty-nine (89) degrees perpendicular to the thermally conductive back of the LED module.

21. The apparatus according to claim 19, further comprising:

a light reflector having mounting tabs perpendicular to a proximal end thereof, wherein the front heat sink surrounds the light reflector;

at least one first mounting channel in an inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

at least one second mounting channel in the inner circumference of the LED module and substantially parallel with the substrate of the LED module; and

at least one third mounting channel in the inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

wherein the at least one first mounting channel, the at least one second mounting channel and the at least one third mounting channel connect at respective ends, and the at least one first mounting channel is open at the face of the LED module for accepting the mounting tabs when the light reflector is inserted into the LED module, then the light reflector is rotated through the at least one second mounting channel to the at least one third mounting channel having a closed end, whereby the mounting tabs are locked into the at least one third mounting channel at the closed end.

22. The apparatus according to claim 21, further comprising at least one spring at the face of the LED module for mechanically biasing the mounting tabs of the light reflector into the at least one third mounting channel.

23. The apparatus according to claim 21, wherein material of the light reflector is selected from the group consisting of metal, molded glass, and reflectively coated plastic.

24. The apparatus according to claim 19, wherein the front heat sink comprises a plurality of heat dissipating fins with air gaps therebetween.

25. The apparatus according to claim 19, wherein the back heat sink comprises a plurality of heat dissipating fins with air gaps therebetween.

26. The apparatus according to claim 19, further comprising thermally conductive material between the thermally conductive back of the LED module and the face of the back heat sink.

27. An apparatus for illumination, comprising:

a light emitting diode (LED) module, the LED module comprising

a thermally conductive back,

a substrate having a plurality of light emitting diodes thereon and electrical connections thereto,

a front,

tapered first sides extending around a circumference of the thermally conductive back and in thermal communication therewith, wherein a back circumference of the tapered first sides is less than a front circumference of the tapered first sides, and

tapered second sides extending around a circumference of the front of the LED module, wherein a front circumference of the tapered second sides is less than a circumference where the tapered second sides and the tapered first sides meet;

a back heat sink having a front face;

an interposing heat sink having front and rear faces and an opening with tapered sides protruding through the interposing heat sink, the opening is centered in the interposing heat sink, wherein the tapered first sides of the LED module fit into the opening of the interposing heat sink such that the tapered first sides of the LED module are in thermal communication with the corresponding tapered sides of the opening in the interposing heat sink;

a front heat sink having a rear face and a cavity with sides protruding into the front heat sink, the cavity is centered in the front heat sink and is open toward a front face of the front heat sink, wherein the LED module fits into the cavity in the front heat sink such that the tapered second sides of the LED module are in thermal communication with corresponding tapered sides of the cavity; and

the front, interposing and back heat sinks are attached together and in thermal communication, wherein the front and interposing heat sinks hold the LED module to the back heat sink.

28. The apparatus according to claim 27, wherein an angle of the tapered first sides of the LED module are from about five (5) degrees to about thirty (30) degrees perpendicular to the face of the LED module.

29. The apparatus according to claim 27, further comprising:

a light reflector having mounting tabs perpendicular to a proximal end thereof, wherein the front heat sink surrounds the light reflector;

at least one first mounting channel in an inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

at least one second mounting channel in the inner circumference of the LED module and substantially parallel with the substrate of the LED module; and

at least one third mounting channel in the inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

wherein the at least one first mounting channel, the at least one second mounting channel and the at least one third mounting channel connect at respective ends, and the at least one first mounting channel is open at the face of the LED module for accepting the mounting tabs when the light reflector is inserted into the LED module, then the light reflector is rotated through the at least one second mounting channel to the at least one third mounting channel having a closed end, whereby the mounting tabs are locked into the at least one third mounting channel at the closed end.

30. The apparatus according to claim 29, wherein there are three each of the first, second and third mounting channels.

31. The apparatus according to claim 29, further comprising at least one spring at the face of the LED module for mechanically biasing the mounting tabs of the light reflector into the at least one third mounting channel.

32. The apparatus according to claim 29, wherein the interposing heat sink comprises a plurality of heat dissipating fins with air gaps therebetween.

33. An apparatus for illumination, comprising:

a light emitting diode (LED) module, the LED module comprising;

a thermally conductive back,

a substrate having a plurality of light emitting diodes thereon and electrical connections thereto, and

tapered sides extending around a circumference of the thermally conductive back and in thermal communication therewith, wherein a back circumference of the tapered sides is less than a front circumference of the tapered sides;

a back heat sink having a front face and a cavity with sides protruding into the back heat sink, the cavity is centered in the back heat sink, open at the front face of the back heat sink and closed at a back of the cavity away from the front face of the back heat sink, wherein the LED module fits into the cavity in the back heat sink such that the tapered sides of the LED module are in thermal communication with corresponding tapered sides of the cavity, and the back of the cavity in the back heat sink is in thermal communication with the thermally conductive back of the LED module; and

a front heat sink having a rear face and an opening therethrough, wherein the front face of the back heat sink and the back face of the front heat sink are in thermal communication.

34. The apparatus according to claim 33, further comprising:

a light reflector having mounting tabs perpendicular to a proximal end thereof, wherein the opening of the front heat sink surrounds the light reflector;

at least one first mounting channel in an inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

at least one second mounting channel in the inner circumference of the LED module and substantially parallel with the substrate of the LED module; and

at least one third mounting channel in the inner circumference of the LED module and substantially perpendicular to the substrate of the LED module;

wherein the at least one first mounting channel, the at least one second mounting channel and the at least one third mounting channel connect at respective ends, and the at least one first mounting channel is open at the face of the LED module for accepting the mounting tabs when the light reflector is inserted into the LED module, then the light reflector is rotated through the at least one second mounting channel to the at least one third mounting channel having a closed end, whereby the mounting tabs are locked into the at least one third mounting channel at the closed end.

35. The apparatus according to claim 33, further comprising at least one spring at the face of the LED module for mechanically biasing the mounting tabs of the light reflector into the at least one third mounting channel.